Optimisation of Weld Overlay for Productivity and Corrosion

Resistance

PUBLISHABLE
SUMMARY

21450

Background

Corrosion-resistant weld overlays are often used to improve the service life
of components made with an otherwise corrosion-prone material. One of
the major concerns in arc welding overlay is dilution. Many of the Codes
and Standards restrict heat input to control dilution. However, a required
heat input can be achieved by proportionally varying the welding current
and the welding speed, both of which will have entirely different effects on
dilution. Hence the above stipulation is not adequate for ensuring the
chemistry of the weld overlay and its integrity. Due to uncertainties
involved in the quality of the weld overlay, a conservative approach is
taken when specifying the permissible dilution, resulting in substantial
productivity losses, and increase in cost and associated issues such as
distortion of components.

Improved process control has been achieved with new generation arc
welding equipment through digital control, giving the benefits of reduced
heat input and improved arc stability. Hence, the consistency of weld
quality achieved is much greater than that achieved with conventional
equipment. In addition, a TWI investigation, on alloy 625 weld overlay
using a corrosion testing technique which sampled individual weld beads
on weld overlay, showed that the corrosion resistance was maintained at
significantly higher levels of Fe in the weld overlay than the current limits
followed in the industry. Thus, there appears to be an opportunity for
relaxing the current permissible limits for %Fe in the weld overlay.

This JIP was undertaken to identify the effect of different Fe content on

corrosion and corrosion fatigue performance of alloy 625 weld overlay on a
carbon steel substrate.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
 Optimisation of Weld Overlay for Productivity and Corrosion
Resistance

Objectives

Identify the effect of varying Fe on corrosion and corrosion fatigue performance of overlay for a range
of simulated environments, including severe sour service.

Investigate the process capability of a set of high productivity weld overlay processes

Benefits

Quantified capabilities of different arc processes, consumables and the influence of process parameters
on dilution have been established. This facilitates the selection of the right process and process
parameters to maximise productivity and performance. For a given environment, it may be possible to
find a cheaper alternative procedure satisfying the environmental conditions, thereby reducing the cost
of overlaying.

Increased confidence in the integrity and the uniformity of the weld overlay will help reduce the
overall corrosion protection cost by reducing the minimum number of layers. The results generated in
this programme may also form the basis for relaxing the current dilution limits specified for a given
service environment.

Industry Sponsors

Petrobras;

Polysoude SAS;

Aquilex Corporation;

ConocoPhillips Company;

Work Completed

Quantified the effect of process variables on dilution in weld overlays produced using hotwire TIG
welding and MIG welding techniques.

Manufactured weld overlays with 5 specified ranges of dilution (5-53% Fe) on carbon steel substrate,
using alloy 625 consumable.

Characterised the electrochemical behaviour of the weld overlays in accordance with ASTM G61.

Determined the critical pitting temperature (CPT) of the weld overlays in accordance with ASTM G150
and ASTM G48-C.

Determined critical crevice temperature (CCT) according to ASTM G48 Method D.

Carried out SCC tests in 25%wt NaCl solution containing H2S and CO2 at 177C and 53bara.

Carried out corrosion fatigue testing in air and sour environment to identify the effect of Fe content on
corrosion fatigue resistance.

Investigated the process capability of MIG and tandem MIG welding processes.

Investigated the influence of welding position on productivity and quality of the weld overlay.

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK. Tel: +44 (0)1223 899000
 Optimisation of Weld Overlay for Productivity and Corrosion
Resistance

Project Outcome

This project quantified the effect of Fe content in alloy 625 weld overlay cladding. The results showed that the
current limits on Fe in alloy 625 weld overlay cladding could be relaxed significantly without compromising on
its quality. The results are supported by corrosion and corrosion fatigue data. A review of state-of-the-art
equipment and novel processing and inspection techniques was also provided to sponsors.

Price and Duration

This project had a duration of 3 years and a budget of 400,000. The project results are available for purchase
at a sponsorship fee of 80,000.

Further Information

For further information on how a Joint Industry Project (JIP) runs please visit:

http://www.twi-global.com/services/research-and-consultancy/joint-industry-projects/

JIP Co-ordinator: Kirsty Jones Ref: 21450/11-2/14

Email: jip@twi.co.uk

Project Leader: Vinod Kumar

Email: vinod.kumar@twi.co.uk

Copyright TWI Ltd 2014